Ford announced a recall of 694,271 SUVs in the U.S. and its territories after a yearlong federal investigation identified a potential fire hazard stemming from cracked fuel injectors. The recall includes certain 2021–24 Bronco Sport and 2020–22 Escape models equipped with 1.5-liter engines and will cost the automaker an estimated $570 million, Ford disclosed in a government filing.
According to the National Highway Traffic Safety Administration (NHTSA), the affected injectors may leak fuel into the engine compartment, increasing the risk of fire. Symptoms may include a strong fuel smell, warning lights, smoke or visible flames. While Ford said it is unaware of any injuries related to the defect, it acknowledged eight instances of underhood fires, some in vehicles previously repaired under earlier recalls.
“This safety recall ... will include a new remedy for this issue, which is currently under development and expects to be finalized in the near future,” Ford spokesperson Mike Levine told the Detroit Free Press.
In the meantime, dealers will provide an interim software update to detect cracked injectors and mitigate fire risk. Owners will be notified by mail beginning Aug. 18, with second notices to follow once a permanent repair is finalized.
This marks Ford’s 88th recall filing with the NHTSA in 2025—more than any other automaker. The company has consistently led in recall numbers since 2020, raising ongoing concerns about its product quality. Ford’s struggle with quality has affected its leadership: CEO Jim Farley’s 2024 compensation was reduced by $1.6 million after failing to meet quality improvement goals.
The company has also faced regulatory scrutiny. In November 2024, Ford agreed to pay up to $165 million — the second-largest civil penalty in NHTSA history — after investigators concluded the automaker delayed recalling vehicles with faulty rearview cameras and submitted incomplete recall information.
The recalled vehicles were supplied with injectors manufactured by Italy-based Dumarey Flowmotion Technologies. This action expands on recalls from 2022 and 2024 that covered around 42,000 vehicles but failed to fully address the root cause of the issue. A 2024 NHTSA query determined the software-based fixes did not resolve the mechanical defect.
Ford said the financial impact of the latest recall will be booked as a special item in its second-quarter earnings report, scheduled for release on July 30. Analysts expect the company’s earnings to decline year over year.
Customers affected by the recall can contact Ford customer service at 866-436-7332 and reference recall number 25S76 for further information.
Check for open recalls on any vehicle using a VIN or license plate number at www.nhtsa.gov/recalls.
